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Complex Optics Prototypes Created With Additive Manufacturing From Gray Optics

Date Announced: 08 Jul 2022

Gray Optics’ Additive Manufacturing experience combines component and optical design expertise with highpower additive laser metal manufacturing. Applications for these highly complex parts include dental implants to industrial parts, which are too difficult for lathe or millwork, and now are made with a metal powder bed fusion system. Melt pool diagnostics and calibration of your existing 3D
printer are also available through the Gray Optics team with the development of additional sensors.

Fully custom 3D printer systems with customer-controlled parameters and diagnostic sensors are
also available for OEM manufacturers that require even more precise control over their
technology. Gray Optics helps customers optimize the beam quality (shape and size) through
detailed optical and mechanical modeling that follows a detailed Product Development Process.

“3D additive manufacturing allows for complex geometries, weight savings, and time savings.
The process allows engineers to design the part in CAD software and directly export to the
printing platform for fabrication. Our team supports development calibration and in-situ, realtime monitoring systems to optimize machine operation,” states Dan Gray, Owner, and Founder.
“Our team forms a collaborative partnership at every stage of the product development process.”

One example of this technology from Gray Optics is the development of customer in-situ quality
control measurements. 

The Problem: The existing optics used in the customer’s melt pool monitoring detection module
did not provide the optimal spectral response, light transmission, and reflectivity efficiency that
enabled high signal-to-noise (S/N) measurements. This insufficiency limited the end customer’s
ability to accurately measure and understand how the build process progressed in real-time.

The Solution: Gray Optics developed a custom dichroic beamsplitter to provide high
transmission of the laser light and high reflectivity over the most critical spectral ranges. The
dichroic beamsplitter was designed to work with kilo-watt NIR lasers to ensure it would perform
to specification under continuous use over the build process without laser damage. In addition,
the developed coatings have been certified to continuously operate at significantly higher power
densities offering adequate safety margin to support even higher laser products in the future.
Partner with Gray Optics for your subsequent OEM instrument product development. Learn
more at GrayOptics.com

Gray Optics was established in 2018 in Portland, Maine, to bring engineering development and
prototype advancements to the surgical, life sciences, and industrial optics marketplace. Product
engineering, assembly, measurement, and testing teams handle each custom problem-solving
target as an independent innovation partnership, finding the optimal solution for each challenge.
The mission at Gray Optics is to change, improve, and save lives by developing new optical
products for the medical, life sciences, and industrial markets.

Learn more about Gray Optics.


Amanda MacDonald
Full Gallop Communications

E-mail: hello@fullgallopcomm.com

Web Site: https://www.grayoptics.com/

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